System to monitor an amount of material in a container

ABSTRACT

Embodiments of the disclosure pertain to a system effective to monitor an amount of a material, the system includes a portable container, the material is within the portable container; a sensor operatively associated with the portable container, the sensor effective to detect a first level of the material in the portable container when the portable container is at a first location and to generate a first data signal based on the first level, and the sensor is also effective to detect a second level of the material in the portable container and to generate a second data signal based on the second level; a processor in communication with the sensor, the sensor is able to communicate the first data signal and the second data signal to the processor, and the processor is effective to receive the data signals, and effective to generate a report based on the first data signal and the second data signal.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND

1. Field of the Disclosure

This disclosure relates to a system and method for monitoring chemicals,such as fracturing chemicals, agriculture chemicals or any other relatedindustries, stored in portable containers.

2. Background of the Disclosure

In a subterranean stimulation formation process, such as fracturing, oneor more chemicals may be applied to a subterranean formation. Thechemicals may each be stored in respective containers. As the formationprocess continues, an amount of each chemical in a respective containerwill change. Eventually, at least some of these chemicals may need to bereplenished.

SUMMARY

Embodiments of the disclosure pertain to a system effective to monitoran amount of a material that may include a portable container, whereinthe material may be within the portable container; a sensor operativelyassociated with the portable container, the sensor may be effective todetect a first level of the material in the portable container when theportable container is at a first location and to generate a first datasignal based on the first level, and the sensor may also be effective todetect a second level of the material in the portable container and togenerate a second data signal based on the second level; and a processormay be communication with the sensor, whereby the sensor may be able tocommunicate the first data signal and the second data signal to theprocessor, and the processor may be effective to receive the first datasignal and the second data signal, and effective to generate a reportbased on the first data signal and the second data signal, the reportrelating to an amount of the material in the container

The processor may be in communication with a database, and the processormay generate a signal when the amount is below a threshold. Theprocessor may be effective to send the report over a network to at leastone of a computer display proximate to the first location, a website,and a mobile application. The report may include information indicatinga location of the portable container, and information about a change inthe amount of the material.

The system may include a plurality of portable containers, each of thecontainers having its respective sensors for measuring material.

The processor may be in communication with a database and the processormay be effective to generate an alarm when the amount of material isbelow a threshold.

The material may be or otherwise include guar or a guar-based material.

The processor may be effective to send the report to a mobile device.

The system may include a plurality of portable containers, each of thecontainers having its respective sensors for measuring material. Theprocessor may be in communication with a database and the processor iseffective to generate an alarm when the amount of material is below athreshold, and the material may include guar.

Other embodiments of the disclosure pertain to an amount of materialthat may include a portable container; a material in the portablecontainer; a sensor associated with the portable container, the sensoreffective to detect a first level of the material defined by a firstamount of the material in the container when the container is at a firstlocation and to generate a first data signal based on the first level,detect a second level of the material defined by a second amount of thematerial in the container and to generate a second data signal based onthe second level, and send the first and second data signal to aprocessor; and a first processor in communication with the sensor, thefirst processor effective to receive the first and second data signaland effective to generate a report based on the first and the seconddata signal, the report relating to an amount of the material in thecontainer; the first processor effective to send the report over anetwork to a second processor.

The report may include information indicating a location of the portablecontainer, and information about a change in the amount of the material.

The processor may be in communication with a database and the processormay be effective to generate an alarm when the amount of material isbelow a threshold.

The system may include a plurality of portable containers, each of thecontainers having its respective sensors for measuring material.

The processor may be in communication with a database and the processormay be effective to generate an alarm when the amount of material isbelow a threshold.

The material may include guar.

The processor may be effective to send the report to a mobile device.

Yet other embodiments of the disclosure pertain to a system effective tomonitor amounts of materials in a plurality of portable containers thatmay include a plurality of containers; a material in each of thecontainers; a sensor associated with each of the containers, each sensoreffective to detect a first level of the material in a respectivecontainer and to generate a first data signal based on the first level,and also detect a second level of the material in the respectivecontainer when the container and to generate a second data signal basedon the second level, and communicate the first and second data signalfrom each of the plurality of containers; and a processor incommunication with the sensors, the processor effective to receive thefirst and second data signal from each of the plurality of containers,determine a change in a level of material in at least one container, andwhen a level in at least one container changes, generate a report basedon the first and the second data signal from each of the plurality ofcontainers, the report including the amount of material in each of theplurality of containers and their geographic location.

The processor may be in communication with a database and the processormay be effective to generate an alarm when the first amount is below athreshold. The system may include a second processor. The firstprocessor may be effective to send the report over a network to thesecond processor. The second processor may be effective to display thereport on a display.

These and other embodiments, features and advantages will be apparent inthe following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of embodiments disclosed herein is obtained fromthe detailed description of the disclosure presented herein below, andthe accompanying drawings, which are given by way of illustration onlyand are not intended to be limitative of the present embodiments, andwherein:

FIG. 1 shows a system drawing of a monitoring system in accordance withan embodiment of the disclosure;

FIG. 2 shows a flow diagram illustrating a process which could beperformed in accordance with an embodiment of the disclosure.

DETAILED DESCRIPTION

Embodiments of the present disclosure are described in detail withreference to the accompanying Figures. In the following discussion andin the claims, the terms “including” and “comprising” are used in anopen-ended fashion, such as to mean, for example, “including, but notlimited to . . . ”. While the disclosure may be described with referenceto relevant apparatuses, systems, and methods, it should be understoodthat the disclosure is not limited to the specific embodiments shown ordescribed. Rather, one skilled in the art will appreciate that a varietyof configurations may be implemented in accordance with embodimentsherein.

Although not necessary, like elements in the various figures may bedenoted by like reference numerals for consistency and ease ofunderstanding. Numerous specific details are set forth in order toprovide a more thorough understanding of the disclosure; however, itwill be apparent to one of ordinary skill in the art that theembodiments disclosed herein may be practiced without these specificdetails. In other instances, well-known features have not been describedin detail to avoid unnecessarily complicating the description.Directional terms, such as “above,” “below,” “upper,” “lower,” “front,”“back,” etc., are used for convenience and to refer to general directionand/or orientation, and are only intended for illustrative purposesonly, and not to limit the disclosure.

Connection(s), couplings, or other forms of contact between parts,components, and so forth may include conventional items, such aslubricant, additional sealing materials, such as a gasket betweenflanges, PTFE between threads, and the like. Embodiments of thedisclosure provide for one or more components to be new, used, and/orretrofitted to existing machines and systems.

Referring now to FIG. 1, there is shown a system 100 effective tomonitor an amount of chemicals in portable containers, in accordancewith embodiments disclosed herein. System 100 includes one or morecontainers 102, a processor 110, and a network 112. Focusing oncontainer 102 a, as illustrative of the containers shown, each container102 may include a level sensor 104 and a chemical material 106. Chemicalmaterial 106 may be a material used in a subterranean formationstimulation process such as fracturing.

Material 106 may include, for example, a carrier fluid, a polymer suchas guar, a cross-linker, a propping agent, non-emulsifiers, formationcleaners, acids, bases, buffers, oxidizers, polymer slurries, enzymes,friction reducers, breakers, temperature stabilizers, boron, zirconium,titanium cross inkers, scale inhibitors, oxygen scavengers, hydrogensulfide scavengers, chemicals used in fracturing, drilling oragriculture, etc.

Level sensor 104 may be effective to monitor a level of chemicalmaterial 106 in container 105. For example, level sensor 104 may be aMASSA M-3 level sensor in a chemical resistant housing with NATIONALPIPE TAPER threads such as a MAGNETROL MODEL R82-516-011 radar head,etc. Level sensor 104 may include an antenna and be capable of sending aspread spectrum radio signal indicative of a level of material 106 incontainer 102. In an example, sensor 104 may be effective to send a datasignal through a communication link 108 to processor 110 every about 0.5to about 60 seconds indicating a level of material 106 in container 102.Sensor 104 may be powered by lithium batteries.

As containers 102 may be portable, processor 110 may receive datasignals relating to levels of material 106 when container 102 is at morethan one location. Processor 110 may process these data signals andgenerate a report, such as on display 122, indicating an amount ofmaterial in container 102.

Communication link 108 may include wireless communication and/or wiredcommunication. Processor 110 may be a master monitoring panel incommunication with a display 122. Processor 110 may include a WST-200radio monitor such as those available from NTE AUTOMATION. The radiomonitor may be effective to receive data through communication link 108and can thereby enable communication between processor 110 andcontainers 102. Processor 110 may generate a report on display 122including a graphical image indicating amounts of material 106 incontainers 102 at multiple times and/or locations. The graphical imagemay indicate an amount of material 106 in container 102, whether theamount of material is changing, whether the amount of material isstatic, and whether the amount is below a threshold percentageindicating that the material should be replenished.

Processor 110 may also send data relating to amounts of materials 106over network 112 to a processor such as a user's phone and/or processor114 so that the processor 112, 114 may be able to generate applicablereports 118, 120. Network 112 may include, for example, a cellularnetwork including cell towers, a satellite network, or directcommunication. Network 112 may include the Internet network andcommunication could be through, for example, TCP/IP (transfer connectprotocol/internet protocol).

Processor 110 may be in communication with a memory 124. Memory 124 mayinclude a list of containers and threshold amounts. When processor 110determines that an amount of a material in a particular container hasdropped below the respective threshold, based on communication withmemory 124, processor 110 may generate an alarm. Processor 110 may sendthe alarm over network 112 to a processor such as smart phone 116 orprocessor 114. For example, processor 110 may generate a phone calland/or text message based on the alarm. A user may view data processedby processor 110 on a display 124 through a web interface usingprocessor 114. For example, information regarding a last delivery to acontainer, the delivery amount, and container level or amount history,may be displayed on display 124 by processor 114.

System 100 may be used with a truck 130 including a cab 126 and trailer128. Processor 110 may be placed in a cab 126 of truck 130 andcontainers 102 may be placed in trailer 128. Processor 110 maycommunicate with a positioning system such as a GPS (global positioningsystem) and thus monitor a location of cab 126 and amounts of materials106 in containers 102. In examples where truck 130 is used, when cab 126is in range of sensor 104 in container 102, processor 110 may record anidentifier of trailer 128 so that processor 110 may keep track of whichcab 126 is attached to which trailer 128. As truck 130 moves, processor110 may generate information regarding a location of truck 130 overtime. As amounts of material 106 are also monitored, processor 110 maygenerate a map of where truck 130 has travelled and when and wherecontainers 102 were filled and/or emptied.

Among other benefits, using a system in accordance with this disclosurea user can realize inventory control of materials anywhere in the world.A system may use bulk storage of chemicals reducing a footprint of afracturing job. Inventory management may be performed at all stages of afracturing process. Inventory records may be kept for years and may bereconciled. Customers may be invoiced quicker. A fracturing job may besafer with fewer spills as fewer hose connections need to be made.Freight charges may be reduced. Inventory adjustments and write offs,man hours, trailer fleet rental, third party hauling, tote disposal, andpartial tote handling, may be reduced. In an example, a system maymeasure 200 different portable containers. Measurement may be made withan accuracy of about 0.05%.

Referring now to FIG. 1, there is shown a process which could beperformed in accordance with an embodiment of the invention. The processcould be performed using, for example, system 100 discussed herein.

As shown, at step S2, a sensor may detect a level of a material in acontainer when the container is at a first location.

At step S4, the sensor may generate a first data signal based on thefirst level.

At step S6, a sensor may detect a level of a material in a containerwhen the container is at a second location.

At step S8, the sensor may generate a second data signal based on thesecond level.

At step S10, a processor in communication with the sensor may receivethe first and the second data signal.

At step S12, the processor may generate a report based on the first andthe second data signal, the report relating to an amount of the materialin the container.

While embodiments of the disclosure have been shown and described,modifications thereof can be made by one skilled in the art withoutdeparting from the spirit and teachings of the disclosure. Theembodiments described herein are exemplary only, and are not intended tobe limiting. Many variations and modifications of the disclosurepresented herein are possible and are within the scope of thedisclosure. Where numerical ranges or limitations are expressly stated,such express ranges or limitations should be understood to includeiterative ranges or limitations of like magnitude falling within theexpressly stated ranges or limitations. The use of the term “optionally”with respect to any element of a claim is intended to mean that thesubject element is required, or alternatively, is not required. Bothalternatives are intended to be within the scope of any claim. Use ofbroader terms such as comprises, includes, having, etc. should beunderstood to provide support for narrower terms such as consisting of,consisting essentially of, comprised substantially of, and the like.

Accordingly, the scope of protection is not limited by the descriptionset out above but is only limited by the claims which follow, that scopeincluding all equivalents of the subject matter of the claims. Each andevery claim is incorporated into the specification as an embodiment ofthe present disclosure. Thus, the claims are a further description andare an addition to the preferred embodiments of the disclosure. Theinclusion or discussion of a reference is not an admission that it isprior art to the present disclosure, especially any reference that mayhave a publication date after the priority date of this application. Thedisclosures of all patents, patent applications, and publications citedherein are hereby incorporated by reference, to the extent they providebackground knowledge; or exemplary, procedural or other detailssupplementary to those set forth herein.

What is claimed is:
 1. A system effective to monitor an amount of achemical material, the system comprising: a plurality of portablecontainers, wherein the chemical material is within at least one of theportable containers; a sensor operatively associated with the at leastone of portable containers, the sensor effective to detect a first levelof the chemical material in the at least one portable container when theat least one portable container is at a first location and to generate afirst data signal based on the first level, and the sensor is alsoeffective to detect a second level of the chemical material in the atleast one portable container and to generate a second data signal basedon the second level; and a processor in communication with the sensor,whereby the sensor is able to communicate the first data signal and thesecond data signal to the processor, and the processor is effective toreceive the first data signal and the second data signal, and effectiveto generate a report based on the first data signal and the second datasignal, the report relating to an amount of the chemical material in theat least one container; wherein the processor is in communication with adatabase, and the processor generates a signal when the amount is belowa threshold, wherein the processor is effective to send the report overa network to at least one of a computer display proximate to the firstlocation, a website, and a mobile application, wherein each remainingportable container of the plurality of portable containers comprises atleast one respective sensor associated therewith, wherein the chemicalmaterial is useable in connection with an oilfield operation, andwherein the report further comprises information indicating a locationof the at least one portable container, and information about a changein the amount of the chemical material.
 2. The system of claim 1,wherein the processor is in communication with a database and theprocessor is effective to generate an alarm when the amount of chemicalmaterial is below a threshold.
 3. The system of claim 1, wherein thechemical material comprises guar.
 4. The system of claim 1, wherein theprocessor is effective to send the report to a mobile device.
 5. Thesystem of claim 1, the system further comprising a plurality of portablecontainers, each of the containers having its respective sensors formeasuring chemical material, wherein the processor is in communicationwith a database and the processor is effective to generate an alarm whenthe amount of chemical material is below a threshold, and wherein thechemical material comprises guar.
 6. A system effective to monitor anamount of chemical material, the system comprising: a portablecontainer; a chemical material in the portable container; a sensorassociated with the portable container, the sensor effective to detect afirst level of the chemical material defined by a first amount of thechemical material in the container when the container is at a firstlocation and to generate a first data signal based on the first level,detect a second level of the chemical material defined by a secondamount of the chemical material in the container and to generate asecond data signal based on the second level, and send the first andsecond data signal to a processor; and a first processor incommunication with the sensor, the first processor effective to receivethe first and second data signal and effective to generate a reportbased on the first and the second data signal, the report relating to anamount of the chemical material in the container; the first processoreffective to send the report over a network to a second processor,wherein the report further comprises information indicating a locationof the portable container, and information about a change in the amountof the chemical material, wherein the chemical material is useable inconnection with an oilfield operation, and wherein the system furthercomprises a plurality of additional portable containers, each of theadditional containers having a respective sensor operably configured formeasuring chemical material.
 7. The system of claim 6, wherein theprocessor is in communication with a database and the processor iseffective to generate an alarm when the amount of chemical material isbelow a threshold.
 8. The system of claim 6, wherein the processor is incommunication with a database and the processor is effective to generatean alarm when the amount of chemical material is below a threshold. 9.The system of claim 6, wherein the chemical material comprises guar. 10.The system of claim 9, wherein the processor is effective to send thereport to a mobile device.
 11. A system effective to monitor amounts ofchemical materials in a plurality of portable containers, the systemcomprising: a plurality of containers; a chemical material in each ofthe containers; a sensor associated with each of the containers, eachsensor effective to detect a first level of the chemical material in arespective container and to generate a first data signal based on thefirst level, and also detect a second level of the chemical material inthe respective container when the container and to generate a seconddata signal based on the second level, and communicate the first andsecond data signal from each of the plurality of containers; and aprocessor in communication with the sensors, the processor effective toreceive the first and second data signal from each of the plurality ofcontainers, determine a change in a level of chemical material in atleast one container, and when a level in at least one container changes,generate a report based on the first and the second data signal fromeach of the plurality of containers, the report including the amount ofchemical material in each of the plurality of containers and theirgeographic location, wherein the chemical material is useable inconnection with an operation, wherein the processor is in communicationwith a database and the processor is effective to generate an alarm whenthe first amount is below a threshold, wherein the system furthercomprises a second processor, and the first processor is effective tosend the report over a network to the second processor, and wherein thesecond processor is effective to display the report on a display.